Method of making plastic cushion product

ABSTRACT

A plastic cushion product comprising a flexible polyvinyl chloride skin and a closed-cell polyurethane core which is preferably directly bonded to the polyvinyl chloride skin. A preferred method of making the plastic cushion products comprising: molding and curing the vinyl chloride at temperatures above about 255* F. for a time sufficient to produce an open polyvinyl chloride shell of desired thickness and just sufficient to cure the polyvinyl chloride to its gild or gel stage; molding polyurethane foam at a temperature of at least 350* F. into a shape substantially conforming to the polyvinyl chloride shell; curing a second amount of vinyl chloride at the temperature and time conditions previously described to form a polyvinyl chloride cover such that the polyvinyl chloride shell and cover mate to form a completely enclosed structure; heating the completely enclosed polyvinyl chloride structure containing the polyurethane foam to a temperature of at least 350* F. to completely cure the polyvinyl chloride. The final cure bonds the polyvinyl chloride shell and cover into a substantially continuous skin and bonds the polyvinyl chloride shell and cover to the polyurethane foam to form an essentially unitary cushion product.

tes ta 1 1 [45] Patented Nov. 30, 1971 [54] METHOD OF MAKING PLASTICCUSHION PRODUCT 12 Claims, 8 Drawing Figs.

[52] 11.5. C1 156/306, 156/242, 4/234, 264/45 [51] llnt. (I1 C09j 5/08[50] Field of Search 4/234, 236, 237; 156/242, 306; 264/31, 32, 33, 34,45

[56] References Cited UNITED STATES PATENTS 3,486,967 12/1969 Fisher156/306 X 3,264,382 8/1966 Angell et a1.. 264/46 3,379,800 4/1968 Wert264/45 3,420,363 1/1969 Blickensderfer 206/46 1,784,619 12/1930 Bishop4/236 2,957,793 10/1960 Dickey 154/100 2,966.686 1/1961 Beneke, Jr 4/2343,068,138 12/1962 Friedman 156/212 3,125,346 3/1964 Poltorak... 277/13,133,853 5/1964 Knox... 161/119 3,175,863 3/1965 Hood 297/455 3,193,4417/1965 Schafer 161/159 3.216.068 11/1965 Williams;

Primary Examiner-Reuben Epstein Allorne v-Fulwider, Patton, Rieber, Lee& Utecht ABSTRACT: A plastic cushion product comprising a flexiblepolyvinyl chloride skin and a closedcell polyurethane core which isreferabIy directly bonded to the polyvinyl chloride skin.

A preferred method of making the plastic cushion products comprising:molding and curing the vinyl chloride at temperatures above about 255 F.for a time sufficient to produce an open polyvinyl chloride shell ofdesired thickness and just sufficient to cure the polyvinyl chloride toits gild or gel stage; molding polyurethane foam at a temperature of atleast 350 F. into a shape substantially conforming to the polyvinylchloride shell; curing a second amount of vinyl chloride at thetemperature and time conditions previously described to form a polyvinylchloride cover such that the polyvinyl chloride shell and cover mate toform a completely enclosed structure; heating the completely enclosedpolyvinyl chloride structure containing the polyurethane foam to atemperature of at least 350 F. to completely cure the polyvinylchloride. The final cure bonds the polyvinyl chloride shell and coverinto a substantially continuous skin and bonds the polyvinyl chlorideshell and cover to the polyurethane foam to form an essentially unitarycushion product.

PATENTED M11130 19m 3523; 93 1 sum 1 or 2 INVENTOR H04 1. /5 L 140v#asz/v PATENTEnuuvaolsn 13,823,931

SHEEI 2 [1F 2 INVIZNTOR. Hon/5 L. l mv H055 METHOD OF MAKING PLASTICCUSHION PRODUCT BACKGROUND OF THE INVENTION This invention relatesgenerally to plastic cushions and the like and, more specifically, topolyvinyl chloride-polyurethane foam cushion-type articles.

Various applications exist in which it is desirable to have a"cushioned" seat to make sitting more comfortable or where it isdesirable to have cushioned walls to prevent injury to a person fallingagainst such walls. Examples of such applications are stool seats, chairseats, toilet seats, benches and bathtub liners.

Heretofore, the requirement for a cushioned member in some of theseapplications, for example, stool seats and toilet seats, has been met byplacing a padding material such as cotton or various foam materials on ahard base such as wood and stretching a thin skin material such asleather over the padding and attaching the skin to the hard base. Whilethis solution has provided a comfortable seat for a time these cushionshave a number of disadvantages, for example, cracking and tearing of theskin and shifting of the padding. Additionally, such cushion members aregenerally not capable of resisting attack by water and other fluidswhich are spilled on them. The result is that the cushion membersdiscolor and/or lose their cushioning ability. Many of the prior artcushion members have the further disadvantage in that they are usuallyweakened and cracked by sunlight.

SUMMARY OF THE INVENTION The plastic cushion products of this inventioncomprise a flexible polyvinyl chloride skin enclosing and preferablydirectly bonded to a closed-cell polyurethane core. This combination ishighly resilient and substantially returns to its original shape anddimensions even after repeated severe deformation.

Cracking of the cushion surface is substantially eliminated because thepolyvinyl chloride skin is extremely resistant to wear and to sunlight(particularly if an ultraviolet stabilizer is included in the polyvinylchloride). Tearing of the cushion products is retarded because of theinherent ability of polyvinyl chloride to resist tearing and because thepolyurethane core is bonded to the polyvinyl chloride skin thereby, ineffect, reinforcing the skin resistance to tearing. Because of theessentially unitary structure of the cushion products which results fromthe interbonding of the polyvinyl chloride skin and polyurethane core,the foam material does not shift away from points on the cushion towhich pressure is applied. Therefore, substantially uniform support isprovided throughout the cushion products whether tightly or heavilyloaded.

The cushion products of this invention have a further advantage in thattheir color can be widely varied by the addition of coloring agents tothe vinyl chloride from which the polyvinyl chloride skin is made or byaddition of colored matter, for example, spangles to the outer cells ofthe foam core.

Still another advantage to be derived from the cushion products of thisinvention is the ability of these products to firmly hold in placeanchor plates to which hardware, for example, hinges, can be attachedto, in turn, connect the cushions to other components to produce acomplete unit, for example, a toilet seat and cover therefor. Suchanchor plates can be positioned in the cushion products withoutnoticeable loss of resilience.

DESCRIPTION OF THE DRAWING FIG. I is a perspective view of a cushionedtoilet seat and cover of this invention in raised position on a toilet.

FIG. 2 is an exploded perspective view of a mold and cover showingtherebetween the top and backplate sections of a polyvinyl chloride skinand a polyurethane foam core to be enclosed by the polyvinyl chlorideskin.

FIG. 3 is a sectional view of the mold of FIG. 2 taken along the line3-3 and shows the mold filled with vinyl chloride.

LII

FIG. 3a is a partial sectional view of the mold of FIG. 2 taken alongthe line 3a-3a and shows "growth" of a polyvinyl chloride skin outwardlyfrom the mold walls.

FIG. 4 is a partial sectional view of a toilet seat of this inventiontaken along the line 4-4 in FIG. 1.

FIG. 5 is a partial sectional view of a toilet seat of this inventiontaken along the line 5-5 of FIG. I and showing an anchor plate insertedtherein.

FIGS. 6 and 6a are sectional views of an anchor plate such as that shownin FIG. 5 and illustrate successive stages in its formation.

DESCRIPTION OF THE PREFERRED EMBODIMENT Although the plastic products ofthis invention may take various forms, for example, bar stool covers,hand rails, bathtub liners, cushions for furniture such as couches, andtoilet seats, they are all characterized by their compressibility andresilience. Therefore, they will hereinafter, and in the claims, bereferred to generically as plastic cushion products."

The plastic cushion products of the present invention comprise, ingeneral, a polyvinyl chloride outer skin and an inner polyurethane foamcore. In the preferred structure, the contacting surfaces of thepolyvinyl chloride skin and the polyurethane core are bonded together bya mechanical bond. Thickness of the polyvinyl chloride skin and theamount of polyurethane foam may be varied depending upon the use forwhich the products made by this invention are intended. Metalliccomponents may be inserted into the plastic cushions to provide anchorpoints so that such cushions can be attached, for example, by hinges, toother components to make a complete unit.

The plastic cushion products of the present invention are tough,durable, resilient and have substantially 100 percent memory, that is,they return substantially to their initial shape even when severely bentor distorted. These plastic cushion products may also be produced in awide variety of sizes and shapes. These desirable characteristics arebelieved due, not only to the unique combination of polyvinyl chlorideand polyurethane foam, but also to the novel, integral construction ofthe plastic cushion products.

More specifically, the outer skin of the plastic cushion products ismade from flexible" polyvinyl chloride. The flexibility of the "flexiblepolyvinyl chloride may be altered, within limits by employing variouswell-known plasticizers, for example, phthalates and adipates, incombination wit vinyl chloride to produce the desired polyvinylchloride. Flexibility of the polyvinyl chloride is indicated by itshardness. Those portions of the plastic cushion products on which aperson sits or stands have a Shore A hardness between about and about85. Below this range, the flexibility is too high, thereby permittingexcessive movement of the core material which greatly reducescushioning. Above this range, the polyvinyl chloride is too hard toprovide adequate cushioning. Preferably, the Shore A hardness of thepolyvinyl chloride is between about and about 78. Within this range,compressibility and firmness are optimally balanced. For those portionsof the plastic cushion products which are in contact with a supportingstructure, the polyvinyl chloride flexibility can be much-less andgenerally, the Shore A hardness of such sections is about 100.

The thickness of the polyvinyl chloride is variable. However, thepolyvinyl chloride thickness is substantially thicker than that (about0.062 in.) presently generally used for coverings for cushions and thelike. The polyvinyl chloride thickness is between about 0.100 in. andabout 0.250 in. and is preferably about 0.125 in. The thicker polyvinylchloride skin used in this invention increases the rate of recovery ofthe cushion product after it has been deformed.

The skin of the plastic cushion products may be made from one or morepolyvinyl chloride sections. Regardless of the number of polyvinylchloride sections from which a plastic cushion product is fabricated,the skin is essentially continuous and unitary. This unitaryconstruction is accomplished by partially curing vinyl chloride to formthe polyvinyl chloride sections and, thereafter, completely curing thepolyvinyl chloride sections with their edges in abutting contact. Whencompletely cured, the polyvinyl chloride skin is self-supporting, thatis, it does not collapse ifthe core material is removed.

Polyvinyl chloride is the preferred skin material because, in additionto its excellent recovery after being deformed, weatherability,wearability, flexibility and fluid impermeability, it is easy to workwith. This is because no mold release is required to free the polyvinylchloride skin from the mold and, consequently, fewer parts are rejectedand, because it is cured under heat, better control of the skinthickness is possible merely by controlling the gild or gel (partialcure) temperature. Other plastics, such as polyurethane sheet material,may be used in place of the polyvinyl chloride although such materialspresent curing and forming problems.

The core material is a closed-cell polyurethane foam. Preferably, thepolyurethane foam has a density between about l.75 and about 2 poundsper cubic foot. Above this range, the polyurethane foam tends to be toohard to serve as a cushioning material whereas, below this range, thepolyurethane foam tends to flow away from the point of applied pressure.This range may be varied to some extent, about 20 percent, by varyingthe thickness and hardness of the polyvinyl chloride skin.

The polyurethane foam core has dimensions substantially the same as theinterior dimensions of the polyvinyl chloride skin prior to its beinginserted into the skin. lf the polyurethane foam core is smaller thanthe interior of the polyvinyl chloride skin, the amount of cushioningpossible with a cushion of a particular size will be less than maximumsince a vacuum will exist between the skin and core. Additionally,recovery of the polyvinyl chloride skin after being deformed may not becomplete since a smaller polyurethane core cannot aid in expanding theskin to its initial dimensions. if the polyurethane core issubstantially larger than the interior dimensions of the polyvinylchloride skin before being inserted into the skin, the polyurethane willbe substantially compressed even when no pressure is applied to thecushion with the result that substantially less cushioning action ispossible in such a structure.

In the preferred structure, the polyvinyl chloride skin and thepolyurethane foam core are bonded directly to each other. This bond isproduced by completing the cure of the polyvinyl chloride when incontact with the polyurethane foam. The outer cells of the polyurethanefoam act as a sponge when in contact with the partially cured polyvinylchloride so that some of the partially cured polyvinyl chloride entersthe polyurethane foam to form a primarily mechanical bond between thepolyvinyl chloride and polyurethane foam. The presence of a polyvinylchloride-polyurethane foam bond has certain advantages. First, such abond, by making the plastic cushion products substantially integralunits, substantially increases the rate of recovery of the plasticcushion products after they have been deformed. Secondly, if thepolyvinyl chloride skin is punctured, the existence of a bond betweenthe polyvinyl chloride and the polyurethane foam prevents moisture formflowing laterally away from the opening between the polyvinyl chlorideskin and polyurethane core. Additionally, because the outermost cells ofthe polyurethane foam core absorb some polyvinyl chloride moisture isprevented from flowing through the core. This produces a very sanitarystructure which is particularly useful for toilet seats.

The plastic cushion products of this invention will be further describedwith reference to the methods for making such products. For conveniencein describing these methods and to illustrate various modifications andadditions to the products of this invention, reference will hereafter bemade to the production ofa resilient toilet seat.

In general, the preferred method for producing a cushioned toilet seatcomprises: molding and curing vinyl chloride into a polyvinyl chlorideshell having a desired configuration at time and temperature conditionsso that the polyvinyl chloride is not substantially completely cured;molding polyurethane foam so that it substantially conforms to theconfiguration of the aforementioned polyvinyl chloride shell; placingthe molded polyurethane foam into the molded polyvinyl chloride shell,and, thereafter, completely enclosing the polyurethane foam by placing asecond, partially cured, polyvinyl chloride sheet, conforming to theedge contour of the molded polyvinyl chloride shell, in edge contactwith the latter and heating the polyvinyl chloride to a temperature ofatleast about 350 F. to bond the polyvinyl chloride sections together andto bond the polyvinyl chloride sections to the polyurethane foam.

Various plasticizers may be added to one or both of the polyvinylchloride sections prior to initial curing to tailor the strength andresilience of each polyvinyl chloride section. Additionally, variouscoloring agents, for example, metal flakes can be added to thepolyurethane foam to provide a variety of color effects.

More specifically, with reference to the Figures and firstly to FIG. 1,the numeral 10 designates a toilet seat comprising a cover or lid member11 and a seat member 12. The cover member 11 may comprise a polyvinylchloride skin and a polyurethane foam core or it may be a solid plasticlid made from, for example, polystyrene. The cover member 11, when madefrom polyvinyl chloride and polyurethane foam is made in substantiallythe same way as the seat member 12, which is described hereafter, and,therefore, will not be described separately.

The seat member 12 comprises a polyvinyl chloride skin 13 enclosing apolyurethane foam core 14 (FIGS. 2 and 4). The polyvinyl chloride skin13 is comprised of a top or shell section 15 and a backplate section 16.

In the preferred method of making the seat member 12, a mold 17 such asthat shown in FIG. 2 is employed. The mold 17 has a cavity 18 defined bya concave surface 26 and having the same shape as the desired toiletseat member 12. Surfaces 19, 19 of the mold adjacent and extendinglaterally from opposing edges 27, 27' of the cavity 18 are substantiallycoplanar.

The mold 17 is preheated to a temperature of about 350 F. Thetemperature of the mold 17 is not critical. However, it must be highenough to raise the temperature of the vinyl chloride to at least about255 F. and preferably below about 285 F. Above this temperature range,the polyvinyl chloride is affected in such a way that, when thereaftercompletely cured, the polyvinyl chloride discolors. Below thistemperature range, it is difficult to obtain parts of desired thicknesssince the heat transfer through the newly formed polyvinyl chloride atsuch lower temperatures is relatively slow and uneven. Additionally, atcuring temperatures below this range, the partially cured polyvinylchloride is quite sticky and flowable and, in such condition, isabsorbed by the polyurethane foam to such an extend that the polyvinylchloride skin 13 is severely weakened and deformed.

Liquid vinyl chloride is poured into the cavity 18 in the heated mold 17until the surface 28 of the vinyl chloride is approximately level withthe die surfaces l9, 19' to form a liquid vinyl chloride pool 20 asshown in FIG. 3. The vinyl chloride immediately begins to cure(polymerize) from the hot cavity surfaces 26 inwards towards the centerof the liquid vinyl chloride pool 20 as shown in FIG. 3a by the numerals15, 15'.

The vinyl chloride is allowed to cure only long enough to partially curethe vinyl chloride. Such partial curing is not sufflcient to pennithandling ofthe part upon cooling. The degree of cure at this stage. isequal to about 60 percent to percent of the cure of completely curedpolyvinyl chloride. This partially cured state is designated herein andin the claims by the terms gel stage" and gild stage." Using a moldtemperature of about 350 F., about 30 seconds are required to obtain apolyvinyl chloride shell 15 about A: in. thick. When the shell 15 havinga desired thickness is obtained, the remaining uncured liquid vinylchloride 20 (FIG. 3a) is drained off.

The backplate 16 is made in substantially the same way as the topsection except that a different mold (not shown) is used to provide thebackplate with a desired shape and thickness. As with the top section15, the polyvinyl chloride employed to form the backplate is cured onlyto the gild stage.

To produce the polyurethane foam core 14, a piece of polyurethane foamis cut to approximately the desired shape. This partially shaped pieceof polyurethane foam is inserted into a preheated mold similar to thatshown in FIG. 2 (designated 17). A top is placed on the mold containingthe polyurethane foam and heating of the foam continues until thedesired shape is produced. The polyurethane foam is heated to at leastabout 350 F. Below this temperature the polyurethane foam cannot beformed. Substantially above this temperature, for example 400 F. for 5minutes, the foam structure begins to break down thereby reducing boththe density and strength of the foam.

With the die at about 350 F., the polyurethane foam is shaped in about 5minutes. The polyurethane foam is able to withstand such a hightemperature because forming of the polyurethane foam core 14 is carriedout in the substantial absence of air (oxygen) due primarily toformation of a gaseous environment from the gases, for example, freonand carbon dioxide, which are used to form the foam and which arepresent in the foam.

Having formed the top and backplate polyvinyl chloride sections 15, 16,and the polyurethane foam core 14, these components are brought togetherin the mold 17, as shown, in exploded view in FIG. 2. The mold 17 isclosed using a mold cover 17' and heated to bring the polyvinyl chlorideup to at least 350 F. to complete the curing of the polyvinyl chloridesections 15, 16. This results in bonding the top and backplate sections15, 16 together and in bonding the polyvinyl chloride sections l5, 16 tothe polyurethane foam core 14. Heating is continued for a timesufficient to complete the cure. This may be as long as 21 minutes wherehot air is circulated over the mold l7 and mold cover 17 or as short as10 minutes where the mold and cover are immersed in a hot (400 F.) brinebath.

After completion of the final cure cycle, the mold l7 and cover 17' arecooled and the finished part is removed. Within about an additional 24hours at ambient temperature, the part has acquired its full strength.

Where it is necessary to attach the plastic cushion products of thisinvention to other components, for example, a toilet seat member andcover member therefor, an anchor plate 24 (FIG. 5) may be incorporatedinto the part before the final cure. With reference to FIG. 6, this maybe accomplished by bonding a layer of polyvinyl chloride 23 to aprepared metal plate 24. This is done by dipping the plate 24 into avinyl chloride bath (not shown) and then curing the vinyl chlorideadhering to the plate to its gel or gild stage to place a polyvinylchloride layer 23 on the plate. The plate 24 with the polyvinyl chloridelayer 23 thereon is coated a second time with vinyl chloride 25 (FIG.6a) and the thus coated plate is depressed into the polyurethane core14, for example, as shown in FIG. 5.

The various components of the toilet seat member 12, including thepolyvinyl chloride-coated plate 24, are assembled in the mold 17, 17' aspreviously described and as shown in FIG. 2. Because of the presence ofthe polyurethane foam core 14 within the polyvinyl chloride skin 13, themetal plate 24 with polyvinyl chloride and vinyl chloride layers 23, 25is pressed against both the polyurethane foam and the polyvinyl chlorideskin and is thereby held firmly in place. This pressure exerted by thepolyurethane core 14 serves to hold the anchor plate 30 in the desiredposition before curing and gives additional support to the anchor platein the finished product. The assembly is heated to 350 F. to completelycure the polyvinyl chloride and vinyl chloride and, thereby, produce thedesired end product. During this curing cycle, the polyvinyl chloridelayer 23 bonds to the cured vinyl chloride layer 25 and the cured vinylchloride layer 25 bonds to the surrounding polyurethane foam 14 and tothe polyvinyl chloride skin 13. The anchor plate 24 is thus firmly fixedin the toilet seat member 12. Brackets 29 (FIGS. 1 and 5) may beattached to the anchor plate 24 by screws 30 for use in interconnectingthe toilet seat member 12 and the cover member 11.

As thus described, the plastic cushion products of this inventioncomprise, in general, an outer polyvinyl chloride skin bonded to apolyurethane core. The plastic cushion products may also be made byforming polyvinyl chloride in the form of an enclosed shell conformingto the desired product shape without first inserting the polyurethane.This polyvinyl chloride skin is formed in substantially the same way(two step cure) and at substantially the same temperature conditions aspreviously described in connection with forming the polyvinyl chlorideskin 13. However, it is necessary to use a rotating mold when bondingthe gelled polyvinyl chloride sections together to form the skin becausethe polyvinyl chloride in its gelled state, and particularly thebackplate section, cannot support itself without the assistance obtainedfrom the polyurethane foam. Therefore, a rotating mold is used to forcethe polyvinyl chloride sections, in their gelled state, against the molduntil fully cured. Polyurethane may be foamed in place within thepolyvinyl chloride skin by conventional foaming techniques either whenthe polyvinyl chloride skin is still in the gelled state or after it isfully cured.

The latter described methods of producing the plastic cushion productsof this invention are not preferred where it is necessary to insertanchor plates into one or more of the products. This is because specialtechniques have to be employed to position the anchor plate correctlybecause the anchor plate has to be positioned within the polyvinylchloride skin before the polyurethane foam is injected. Therefore, inthe latter methods, and as contrasted with the preferred method, thereis no polyurethane foam to hold the anchor plate in position prior tobonding it in place.

This invention will be further described by the following example:

EXAMPLE Molds to form the top and backplate members of a seat sectionofa toilet seat were preheated to 350 F. for 18 minutes. The molds werethen wiped to remove any dust or small particles and a template was putin place on each mold to control the amount of vinyl chloride pouredinto the molds. Formation of the backplate member was facilitated bymoving the mold on which the backplate member was formed back and forthto ensure the formation of a substantially smooth and uniform backplatemember. Excess vinyl chloride was drained off the molds after thirty toforty seconds. At the end of this time, the top and backplate memberswere quite tacky. Therefore, they were set aside for a few minutes afterwhich time the tackiness had substantially disappeared. When the seatand backplate members were no longer tacky, the templates were removedwithout tearing the polyvinyl chloride.

Polyurethane foam, preformed to conform to the shape of the top memberof the seat, was inserted into the top member. Some liquid vinylchloride was poured around the edges of the foam core to ensure a goodbond between the foam and the polyvinyl chloride top member. Some liquidvinyl chloride was also poured on the foam at a point where an anchorplate was to be placed to provide a good bond between the anchor plateand the polyvinyl chloride skin and foam core. The anchor plate was thenplaced in position on the polyurethane foam core and the backplate moldwas then placed on top of the top member mold to thereby bring thebackplate and top members into edgewise contact. Pressure was applied tothe two molds to bring them tightly together. In process of squeezingthe molds together, excess polyvinyl chloride was squeezed out of themolds. The molds were clamped together and passed, on a conveyor,through an oven set at 550 F. for 18 minutes to complete the cure of thepolyvinyl chloride and vinyl chloride.

After being subjected to the elevated temperature, the molds wereremoved from the oven and allowed to cure for about to 30 minutes afterwhich time the clamps were removed from the molds. The backplate and topmember molds were separated from each other and the completed part wasremoved from the molds and laid on a flat surface to allow additionalcooling and curing.

The resulting seat section was firm, yet resilient, and the polyvinylchloride skin returned quickly to its initial position after beingdeformed.

It will be understood that various modifications can be made in thepresent invention without departing from the spirit of the invention.Therefore, this invention is to be limited only by the scope of theappended claims.

lclaim:

l. A method for making a plastic cushion product comprising steps of:

heating vinyl chloride to its gel stage to form partially curedpolyvinyl chloride sections, said gelled polyvinyl chloride sectionscapable of being formed into a continuous closed skin;

inserting a closed cell polyurethane foam core substantially conformingto the inner dimensions of said polyvinyl chloride sections;

further heating said gelled polyvinyl chloride sections associated toform said closed skin and containing therein said polyurethane foam, toa temperature of a least 350 F. to completely cure said gelled polyvinylchloride sections and to bond said gelled polyvinyl chloride sections toeach other and to said polyurethane foam, whereby a resilient cushionproduct is produced.

2. The method of claim 1 wherein said polyurethane foam core ispreshaped to substantially conform to the inner dimensions of said skinby heating polyurethane foam in a mold at a temperature of 350 F.

3. The method of claim 1 wherein said polyurethane foam core is foamedin place in said polyvinyl chloride skin.

4. The method of claim 1 wherein said polyurethane foam core is foamedin place in said polyvinyl chloride skin after said further heatingofsaid polyvinyl chloride skin.

5. The method of claim 1 wherein said vinyl chloride is heated to atemperature ofat least about 255 F.

6. A method for making polyvinyl chloride-polyurethane foam cushionproducts comprising:

heating liquid vinyl chloride (at a temperature of at least 255 F.) in amold for a time sufficient to produce gelled polyvinyl chloride sheetshaving a desired thickness, said gelled polyvinyl chloride sheetscapable of being formed into a continuous closed skin;

heating closed-cell polyurethane foam at a temperature of at least 350F. in the substantial absence of oxygen for a time sufficient to moldsaid polyurethane foam into a configuration having substantially thesame dimensions as the interior of said skin;

heating said gelled polyvinyl chloride sheets, associated to form saidclosed skin and containing therein said polyurethane foam, to atemperature of at least 350 F. to completely cure said gelled polyvinylchloride sheets and to bond said gelled polyvinyl chloride sheets toeach other and to said polyurethane foam.

7. The method of claim 6 wherein said liquid vinyl chloride is heated toa temperature between about 255 F. and about 285 F.

8. The method of claim 6 wherein said gelled polyvinyl chloride sheetsare between about 60 percent to about percent cured.

9. The method of claim 6 wherein said polyurethane foam is heated to atemperature between about 350 F. and about 400 F.

10. The method of claim 6 wherein said polyurethane foam has a densitybetween about l.75 lb./cu.ft. and about 2.0 lb./cu.ft.

11. The method of claim 6 wherein said thickness of said gelled olyvinylchloride is about O.l25 in. I

12. The method of claim 6 wherein an anchor member lS positioned withinsaid cushion products, said member comprising the further steps of:

bonding a layer of gelled polyvinyl chloride to a metallic sheet to formsaid anchor member; inserting said anchor member between saidpolyurethane foam and said gelled polyvinyl chloride of said skin priorto completely curing said polyvinyl chloride, whereby, after completelycuring said polyvinyl chloride skin, said anchor member is bonded tosaid skin and to said polyurethane foam to be securely positioned insaid cushion products.

2. The method of claim 1 wherein said polyurethane foam core ispreshaped to substantially conform to the inner dimensions of said skinby heating polyurethane foam in a mold at a temperature of 350* F. 3.The method of claim 1 wherein said polyurethane foam core is foamed inplace in said polyvinyl chloride skin.
 4. The method of claim 1 whereinsaid polyurethane foam core is foamed in place in said polyvinylchloride skin after said further heating of said polyvinyl chlorideskin.
 5. The method of claim 1 wherein said vinyl chloride is heated toa temperature of at least about 255* F.
 6. A method for making polyvinylchloride-polyurethane foam cushion products comprising: heating liquidvinyl chloride (at a temperature of at least 255* F.) in a mold for atime sufficient to produce gelled polyvinyl chloride sheets having adesired thickness, said gelled polyvinyl chloride sheets capable ofbeing formed into a continuous closed skin; heating closed-cellpolyurethane foam at a temperature of at least 350* F. in thesubstantial absence of oxygen for a time sufficient to mold saidpolyurethane foam into a configuration having substantially the samedimensions as the interior of said skin; heating said gelled polyvinylchloride sheets, associated to form said closed skin and containingtherein said polyurethane foam, to a temperature of at least 350* F. tocompletely cure said gelled polyvinyl chloride sheets and to bond saidgelled polyvinyl chloride sheets to each other and to said polyurethanefoam.
 7. The method of claim 6 wherein said liquid vinyl chloride isheated to a temperature between about 255* F. and about 285* F.
 8. Themethod of claim 6 wherein said gelled polyvinyl chloride sheets arebetween about 60 percent to about 70 percent cured.
 9. The method ofclaim 6 wherein said polyurethane foam is heated to a temperaturebetween about 350* F. and about 400* F.
 10. The method of claim 6wherein said polyurethane foam has a density between about 1.75lb./cu.ft. and about 2.0 lb./cu.ft.
 11. The method of claim 6 whereinsaid thickness of said gelled polyvinyl chloride is about 0.125 in. 12.The method of claim 6 wherein an anchor member is positioned within saidcushion products, said member comprising the further steps of: bonding alayer of gelled polyvinyl chloride to a metallic sheet to form saidanchor member; inserting said anchor member between said polyurethanefoam and said gelled polyvinyl chloride of said skin prior to completelycuring said polyvinyl chloride, whereby, after completely curing saidpolyvinyl chloride skin, said anchor member is bonded to said skin andto said polyurethane foam to be securely positioned in said cushionproducts.